Saddle made of composite material, in patricular for a bicycle, and method for the manufacture thereof

ABSTRACT

Saddle made of composite material, in particular for a bicycle, which comprises a support structure ( 2 ) provided with a padding ( 3 ) having, associated above it, a seating surface ( 7 ). The support structure ( 2 ) comprises a plurality of first layers ( 8 ) of high-rigidity composite material having an opening ( 11 ) formed centrally wherein and a second layer ( 9 ) of composite material with a rigidity less than that of the first layers ( 8 ), fixed to the latter along a superimposed surface covering the opening ( 11 ) so as to form an elasticaly yielding zone which is preferably located in the prostatic and ischiatic zones of the seat ( 7 ) of the saddle ( 1 ).

TECHNICAL FIELD

[0001] The present invention relates to a saddle made of compositematerial, in particular for a bicycle, and to a method for themanufacture thereof.

BACKGROUND ART

[0002] As is known, saddles of the more conventional type are generallycomposed of a shaped, rigid or semi-rigid body which forms the supportstructure of the saddle and is referred to, in the technical jargon ofthe sector, by the name of “shell”, and of a padding which is arrangedon top of the shell and generally consists of an expanded elastomermaterial such as, for example, polyurethane with or without the additionof material in the form of a gel. The shell also has, mounted underneathit, fixing means for ensuring the connection of the saddle with theframe of the bicycle. These means normally comprise a shaped bar (or apair of shaped bars) fixed to the saddle mounting tube by means ofclamps.

[0003] The padding of the saddle is generally lined with a fabric,leather or other material which essentially performs the function ofensuring a greater seating comfort for the cyclist.

[0004] As is known, in the bicycle sector, for some time there has beena particularly pressing need to provide saddles which are at the sametime comfortable, i.e. are able to ensure seating comfort, and light soas not to penalize excessively the cyclist's performance.

[0005] In order to provide saddles which are particularly light, saddleswithout padding have been manufactured recently, said saddles beingessentially composed of the support structure alone which is integrallymade of particularly strong and light materials such as, for example,composite materials consisting of carbon fibres bonded together in resinmatrices.

[0006] These saddles, although being extremely light and having a goodmechanical strength, in practice have proved to be excessivelyuncomfortable owing to the limited elasticity of the seat.

[0007] In order to improve the comfort of cyclists, more recently thinpaddings have been mounted on top of the carbon-fibre seats, althoughthese still have been unable to solve entirely the problem of excessivelack of comfort.

[0008] Alternatively, already known saddles envisage the use of apadding which is composed of several layers of material with varyingelasticity (including also gel) which are suitably arranged in thevarious zones of the seating surface above the support structure whichis made of rigid or semi-rigid plastic material (for examplepolypropylene) with a substantially constant cross-section. In this way,the distribution of the pressures over the whole of the seating surfaceof the saddle has been significantly improved, thereby benefiting thecomfort of the cyclist, but greatly penalizing the overall lightness ofthe saddle.

[0009] At present, therefore, the problem of providing a saddle which isboth comfortable and extremely light has not been entirely solved. Inparticular, hitherto the function of optimising the seating comfort hasbeen attributed entirely to the padding and the function of reducing,where possible, the overall weight of the saddle has been attributed tothe support structure.

DISCLOSURE OF THE INVENTION

[0010] The main object of the present invention is therefore that ofeliminating the drawbacks of the abovementioned art by providing asaddle made of composite material—in particular for bicycles—which isextremely light and has a very comfortable seating surface.

[0011] Another object of the present invention is in particular that ofproviding a saddle which is constructionally simple and operationallyentirely reliable.

[0012] A further object of the present invention is that of providing asimple and low-cost method for producing a comfortable and light saddle.

[0013] These objects, along with others, are all achieved by the saddle,in particular for a bicycle, which is made of composite material andwhich comprises a support structure provided with a padding having,associated above it, a seating surface. According to the invention, thesaddle in question is characterized in that the support structurecomprises at least one first layer of composite material and at leastone second layer of composite material having a form different from thatof the first layer and fixed thereto along a superimposed surface ofsaid layers, to define portions with varying rigidity on the supportstructure.

[0014] By virtue of the above arrangement according to the invention ithas been possible to combine the features of comfort and lightness in asingle saddle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Further features and advantages of the invention will be moreclearly understood from the detailed description of a preferredembodiment of the saddle which follows, furnished by way of non-limitingexample with the assistance of the accompanying drawings in which:

[0016]FIG. 1 shows a plan view of the saddle according to the presentinvention with some parts removed so that others may be seen moreclearly;

[0017]FIG. 2 shows a cross-sectional side view of the saddle accordingto FIG. 1;

[0018]FIG. 3 shows in schematic form a side view, on a larger scale andcross-sectioned, of the support structure of the saddle according toFIG. 1;

[0019]FIG. 4 shows in schematic form a cross-sectional view of thesupport structure along the line II-II of FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS(S)

[0020] In accordance with the figures of the accompanying drawings, 1denotes in its entirety the saddle forming the subject of the presentinvention.

[0021] Below reference will be made, for the sake of simplicity of thedescription, to a saddle for bicycles, it being understood, however,that it may also be mounted on cycles, motorcycles or other vehicles ofany kind.

[0022] The saddle 1 is essentially composed of a rigid or semi-rigidframe 2 forming the support structure of the saddle and referred to inthe technical jargon of the sector by the name of “shell”, and of anelastically yielding padding 3 mounted on top of the shell 2 andconsisting preferably of an expanded elastomer material.

[0023] Preferably the padding 3 is made using an expanded elastomermaterial (polyurethane) with or without injection of material in gelform and is covered with a lining of fabric, leather or other materialable to limit the amount of sweating of the cyclist.

[0024] With particular reference to the accompanying FIG. 2, the shell 2has a bottom surface 4 to which are connected fixing means able toensure the connection of the saddle 1 with a support frame of thebicycle (not shown since of the type known per se) and an upper surface6 onto which the padding 3 able to define at the top the seating surface7 for the cyclist is fixed.

[0025] The fixing means, which are not shown in the accompanyingfigures, are generally obtained by means of a shaped bar which is foldedonto itself (fork) or by means of a pair of shaped bars which are fixedto the saddle mounting tube by means of clamps.

[0026] Advantageously, these shaped bars will be made of carbon fibreand will have variable cross-sections, in particular a widercross-section in the region of the saddle mounting tube in order toallow for the various tensional forces to which it is subject.

[0027] According to the invention, the support structure 2 is formed bymeans of one or more first layers 8 consisting of high-rigiditycomposite material and by means of a second layer 9 consisting oflower-rigidity composite material which is fixed to the first layer 8along a superimposed surface 10. The first and the second layers 8 and 9cover different areas and therefore define portions of varying rigidity.

[0028] More particularly, in accordance with a preferred embodiment ofthe present invention, the support structure 2 is composed of aplurality of first layers 8 each provided with an opening 11 locatedsubstantially in a central zone of the saddle 1. This opening 11 iscovered only by the second lower-rigidity layer with a relatively highelasticity. Thus an elastically yielding zone is defined in the regionof this opening 11.

[0029] Obviously, without departing from the scope of protection of thepresent invention, it will nevertheless be possible to cover the opening11 with a first layer 8 instead of a second layer 9 with less rigiditysince the elastic effect which can be associated with this zone may inany case be obtained owing to the smaller number of layers of compositematerial, i.e. to the reduced thickness of the support structure 2 inthe region of this opening 11.

[0030] Advantageously, this elastically yielding zone is positioned inthe prostatic zone of the seat 7 of the saddle 1 and/or in the ischiaticzones of the seat 7 of the saddle 1.

[0031] For this purpose, this elastically yielding zone may, forexample, have a form comprising two rear lobes 11′ located in theischiatic zones of the seat 7 of the saddle 1 and a central lobe 11″extending in the prostatic zone of the seat 7 of the saddle 1.

[0032] Structurally, as shown in the accompanying FIGS. 3 and 4, thefirst layers 8 have a substantially similar form and dimensions whichbecome smaller layer-by-layer so as to create a support structure 2 ofvariable thickness, which is thinner along its peripheral edge.

[0033] In accordance with the example of embodiment illustrated in FIGS.3 and 4, the second layer 9 is fixed between two first layers 8.

[0034] Constructionally the first layer 8 preferably consists of carbonfibres bonded to an epoxy matrix (and more generally composite-materialfibres commonly called “high-modulus fibres”), while the second layer 9consists of kevlar and polyester fibres bonded to a polyurethane-basedmatrix (and more generally composite-material fibres commonly called“high-elongation fibres”). In this way the first layer has a relativelyhigh rigidity, while the second layer has a relatively high elasticity.

[0035] Advantageously, moreover, the fibres which make up the variousfirst layers 8 may be oriented in variable directions in order to obtainthe maximum mechanical performance.

[0036] In particular, for example, alternate first layers 8 with fibresoriented longitudinally, transversely and at 45° with respect to thelongitudinal axis of the saddle may be envisaged.

[0037] The second layer 9 will have preferably a longitudinalorientation of the kevlar fibres and a transverse arrangement of thepolyester fibres.

[0038] The present invention also relates to a method for themanufacture of a saddle 1 made of composite material, in particular fora bicycle, of the type comprising conventionally a step involvingmoulding, in a mould, of the polyurethane cover 3 on the supportstructure 2.

[0039] More particularly, a mould consisting of a male part, to whichthe support structure is applied, and a female part, which is suitablecovered with a lining, is used during this step.

[0040] The abovementioned moulding step then envisages the insertion ofpolyurethane into the mould and closing of the latter.

[0041] According to the method in question, the manufacture of thesupport structure 2, intended to be inserted into the mould once formed,comprises a step involving hollow-punching of the first layers 8 made offabric consisting of a high-rigidity composite material withsimultaneous or subsequent formation of the opening 11 in each layer 8.

[0042] The various first layers 8 will preferably have dimensions whichare slightly different and gradually decreasing, while maintaining thesame central opening 11. For this purpose, hollow punches with a cuttingblade defining different sections may be envisaged for example.

[0043] Similarly, hollow-punching of a second layer of fabric consistingof a composite material with a rigidity less than that of the firstlayer will also be envisaged, without, however, the formation ofopenings therein.

[0044] At this point, there will follow a step involving thesuperimposition, on top of each other, of the first layers 8 havingdifferent dimensions in such a way as to ensure that the central opening11 is well-defined, creating a thinning effect along the edges.

[0045] Finally, there will follow a step involving the moulding andfixing of the various layers 8 and 9 inside a special mould by means ofa thermosetting resin.

[0046] The first layers 8 are advantageously pre-impregnated with anepoxy resin which is able to cross-link rapidly at a temperature ofbetween 70° and 100° C. The second layer 9 is also advantageously of thetype preimpregnated with resin (for example polyurethane) and thereforeonce the layers 8 and 9 have been placed in the mould, the latter isclosed with a suitable pressure and, by means of heating and coolingmeans associated therewith, complete moulding of the support structureis performed.

[0047] Advantageously, during this mould forming step, the grooves andthe lugs necessary for mounting subsequently the fixing means and inparticular the shaped bars are also formed on the bottom surface 4 ofthe support structure 2.

[0048] In accordance with the example of embodiment illustrated in FIGS.3 and 4, during the superimposition step, firstly a first layer 8 isarranged in the mould, then a second layer 9 is superimposed on thislayer and the remaining first layers 8 are superimposed on the latter.

[0049] The mutual fixing of the layers inside the mould may be achievedas a result of the thermosetting resin with which the said layers areimpregnated or by means of injection of resin inside the mould.

[0050] Advantageously the support structure 2, once extracted from themould, may undergo finishing steps aimed at eliminating, for example,the presence of any burrs.

[0051] The invention thus conceived therefore achieves the pre-setobjects.

[0052] Obviously, it may assume, in its practical embodiment, forms andconfigurations different from that illustrated above without, thereby,departing from the present scope of protection.

[0053] Moreover, all the details may be replaced by technicallyequivalent elements and the dimensions, the forms and the materials usedmay be of any nature depending on requirements.

1. Saddle made of composite material, in particular for a bicycle, ofthe type comprising a support structure (2) provided with a padding (3)having, associated above it, a seating surface (7), characterized inthat said support structure (2) comprises at least one first layer (8)of composite material and at least one second layer (9) of compositematerial having a form different form that of said first layer (8) andfixed thereto along a superimposed surface (10) of said layers, todefine portions with varying rigidity on said support structure (2). 2.Saddle made of composite material according to claim 1, characterized inthat it comprises a plurality of first layers (8) which are superimposedand fixed together and each of which is able to define at least oneopening (11) inside which said second layer (9) is located so as toprovide an elastically yielding zone.
 3. Saddle made of compositematerial according to any one of the preceding claims, characterized inthat said first layer (8) is made from a high-rigidity compositematerial and in that said second layer (9) is made from a compositematerial with a rigidity less than that of said first layer 18). 4.Saddle made of composite material according to claim 2, characterized inthat said opening (11) has a form comprising two rear lobes (11′) whichare located in the ischiatic zones of the seat (7) of the saddle (1). 5.Saddle made of composite material according to claim 2, characterized inthat said opening (11) has a form comprising a central lobe (11″)arranged in the prostatic zone of the seat (7) of the saddle (1). 6.Saddle made of composite material according to claim 2, characterized inthat said first superimposed layers (8) have forms which aresubstantially similar and dimensions which become smaller towards saidpadding (3).
 7. Saddle made of composite material according to claim 2,characterized in that said second layer (9) is fixed between two saidfirst layers (8).
 8. Saddle made of composite material according toclaim 1, characterized in that said first layer (8) is composed ofcarbon fibres bonded to an epoxy matrix.
 9. Saddle made of compositematerial according to claim 1, characterized in that said second layer(9) is composed of kevlar fibres bonded to a polyurethane-based matrix.10. Saddle made of composite material according to claim 1,characterized in that said second layer (9) is composed of kevlar andpolyester fibres bonded to a polyurethane-based matrix.
 11. Saddle madeof composite material according to claim 1, characterized in that saidpadding (3) comprises a cover made of expanded elastomer material. 12.Saddle made of composite material according to claim 11, characterizedin that portions of material in gel form are arranged inside said coverof expanded elastomer material.
 13. Saddle made of composite materialaccording to claim 2, characterized in that at least one of said firstlayers 18) is composed with fibres oriented in a direction differentfrom that of the longitudinal axis of the saddle.
 14. Saddle made ofcomposite material according to claim 1, characterized in said supportstructure (2) is connected to a saddle mounting tube by means of atleast one shaped rod-like element made of carbon fibre.
 15. Saddle madeof composite material, in particular for a bicycle, of the typecomprising a support structure (2) provided with a padding (3) having,associated above it, a seating surface (7), characterized in that saidsupport structure (2) is obtained by means of a plurality of differentlyformed superimposed layers (8) of composite material fixed togetheralong superimposed surfaces (10), said layers (8) defining at least oneelastically yielding zone formed by a smaller number of saidsuperimposed layers (8).
 16. Method for the manufacture of a saddle madeof composite material, in particular for a bicycle, of the typecomprising a step involving moulding, in a mould, of a cover (3) made ofexpanded elastomer material on top of a support structure (2),characterized in that it comprises the following operating steps: firsthollow-punching of one or more first layers (8) of fabric consisting ofhigh-rigidity composite material, defining substantially the profile ofthe support structure (2); formation of at least one opening (11) insidesaid first layers (8); second hollow-punching of at least one secondlayer (9) of fabric consisting of composite material with a rigidityless than that of said first layer (8); superimposition of said firstlayers (8) and said second layer (9) inside a mould; moulding and fixingof said first and second layers (8, 9) inside said mould by means of athermosetting resin.
 17. Method according to claim 16, characterized inthat said superimposition step envisages the arrangement of a firstlayer (8) inside the mould, the superimposition of said second layer (9)on top of said first layer (8) and the superimposition of the remainingfirst layers (8) on top of said second layer (9).
 18. Method accordingto claim 16, characterized in that said step of moulding and fixing saidfirst and second layers (8, 9) inside said mould is achieved using thethermosetting resin with which the individual layers arepre-impregnated.
 19. Method according to claim 16, characterized in thatsaid step of moulding and fixing said first and second layers (8, 9)inside said mould is achieved by means of injection of resin inside themould.